Aromatic polyamides and polyesters containing ortho-ether groups

ABSTRACT

Described herein are polyesters and polyamides which contain repeat units derived from novel dicarboxylic acids comprising arylene groups having ortho ethers substituted thereon. Also disclosed are novel compounds from which these polymers can be made. The polymers are especially useful for molding resins and coatings.

This is a continuation-in-part of Ser. No. 08/664,630, filed on Jun. 18, 1996, now abandoned.

FIELD OF THE INVENTION

Described herein are novel polyesters and polyamides derived from aromatic dicarboxylic acids, or their reactive equivalents, which contain paired ether groups ortho in position to one another on an aromatic portion of such polymers. Also disclosed are novel monomers from which these polymers can be made.

TECHNICAL BACKGROUND

It is well known that polyesters and polyamides are important items of commerce, useful as fibers, molding resins, in coatings, for films, and many other uses. Therefore, new polyesters or polyamides with useful properties are constantly being sought. For example, many polyesters and polyamides are not readily soluble in organic solvents, making them less useful in solvent-based coatings.

U.S. Pat. No. 4,229,566 and R. C. Evers, et al., Macromolecules, vol. 14, p. 925-930 (1982) describe the preparation of certain dinitriles which are subsequently used to prepare polybenzoxazoles. No polyesters or polyamides are described in these references.

Many of the polyamides and polyesters claimed herein, while having various uses, are readily soluble in organic solvents, making them especially useful for coatings.

SUMMARY OF THE INVENTION

This invention concerns a polymer comprising the repeat unit: ##STR1## wherein Ar¹ is arylene or alkyl- or halo-substituted arylene and in which said ether oxygen atoms are substituted on Ar¹ in ortho positions; and, furthermore, said polymer comprises at least one other repeat unit such that the polymer is a polyester, a fusible polyamide or a poly(amide-ester).

The invention also concerns an embodiment, wherein the variables are as described above, of the structure: ##STR2##

The invention also concerns a compound of the formula ##STR3## wherein: Ar¹ is o-phenylene, alkyl substituted o-phenylene, or halogen substituted o-phenylene (wherein "o" indicates ortho);

Y is --CN, --CO₂ H, CO₂ R¹ or COX;

R¹ is hydrocarbyl containing 1 to 20 carbon atoms; and

X is halogen.

DETAILS OF THE INVENTION

In the polymers according to the present invention, the above-described repeat unit (I) is part of a polyester, polyamide or poly(amide-ester). The other repeat unit(s) in the polymer may be one or more of --O--R² --O-- (V), --R³ N--R² --NR³ -(VI), or --O--R² --NR³ -(VII), which are derived, respectively, from a diol, diamine or hydroxyamine. In these formulas, each R² is independently hydrocarbylene or substituted hydrocarbylene, and each R³ is independently hydrogen, hydrocarbylene, or substituted hydrocarbylene. By hydrocarbylene is meant a univalent radical containing only carbon and hydrogen. Preferably, said hydrocarbylenes have 1 to 10 carbon atoms. By "substituted" herein is meant that a specified radical may contain one or more substituents which do not interfere with the formation of the polymer. Preferably, R² is arylene and, more preferably, it is phenylene, especially o-, m- or p-phenylene. R³ is preferably hydrogen. Although other peat units may also be present (for example, repeat units derived from other dicarboxylic acids, diols, diamines and/or hydroxyamines), it is preferred that one or more of the repeat units corresponding to (II), (III) and (IV) alternate with one or more of the repeat units (V), (VI), and (VII). It is also preferred that only one of the repeat units corresponding to (II), (III) or (IV) and/or only one of the repeat units (V), (VI) or (VII) are present in any particular polymer. Preferably, at least 80 percent, more preferably at least 90 percent, on a molar basis, of the total repeat units in the polymer are selected from those according to the above formulas (I) to (VII).

In repeat unit (I), Ar¹ is arylene. By arylene herein is meant a divalent radical containing at least one aromatic ring, preferably having 6 to 10 aromatic ring carbon atoms, in which the free valencies of the radical are to aromatic ring carbon atoms. In this case, the ether groups are ortho to one another on Ar¹, that is, each of the ether oxygen atoms are bound to carbon atoms adjacent to one another in an aromatic ring. Preferred arylene groups Ar¹ are o-phenylene and 2,3-naphthylene. The arylene groups Ar¹ may be substituted with one or more alkyl groups and/or one or more halogens. Preferred alkyl groups preferably have 1 to 10 carbon atoms, more preferably, 1 to 6 carbon atoms. Especially preferred alkyl groups are methyl and t-butyl. Fluorine is a preferred halogen. Preferred substituted arylene groups Ar¹ are 3,4-di-t-butyl-o-phenylene, 3-fluoro-o-phenylene, and 4-t-butyl-o-phenylene.

The polyesters, polyamides and poly(amide-esters) described herein can be made by standard methods known to the artisan. See, for instance, Examples 25-29 below. These polymers are useful for molding resins for making parts, such as electronic connectors, for fibers, for films, and especially for coatings, since many of them are soluble in organic solvents.

For compounds (II) and (III) herein, the same substitution of the o-phenylene group Ar¹ is preferred as for the Ar¹ in repeat unit (I). For compounds (II), (III) and (IV), it is preferred that both of Y are the same. It is also preferred that X is chlorine or R¹ is an alkyl group containing 1 to 6 carbon atoms. In compound (IV), it is preferred that both of Y be in the same positions on their respective phenyl rings relative to the ether oxygen atoms bound to those phenyl rings, i.e., that (IV) be symmetrical.

Compounds of the formulas (II), (III) and (IV) can be made by methods illustrated in the Examples herein provided. The various Y groups may be interconverted to one another by methods known in the art. Compounds (II), (III) and (IV) are useful as monomers for making the polymers herein described, or may be used as intermediates for making monomers for the polymers herein described.

In the Examples that follow, the following abbreviations are used (other abbreviations are defined in the Examples themselves or the Tables that follow):

DMAC--N,N-dimethylacetamide

DMF--N,N-dimethylformamide

NMP--N-methylpyrrolidone

THF--tetrahydrofuran

EXAMPLE 1 Preparation of 1,2-bis-(4-cyanophenoxy) benzene

In a three-necked flask equipped with a magnetic stirring bar, thermometer and a Dean-Stark trap connected to a reflux condenser, there was placed 11.0 g (0.1 mole) of catechol, 150 mL NMP, 24.2 g (0.2 mole) of 4-fluorobenzonitrile, 26 g anhydrous potassium carbonate and 30 mL toluene. The contents of the flask, while stirred, were brought to the boil and water was collected in the Dean-Stark trap. The temperature in the flask was 140° C. Boiling was continued for 6 hours after the evolution of water ceased and toluene was then distilled off, while the temperature in the flask rose to 200° C. The contents were poured into 1.5 l of cold, stirred water. The precipitate (brown mud) was filtered off and washed several times with deionised water. While wet, with water, the product was recrystallized from methanol, yielding 24.8 g (79.5%) of light brown crystals. The crystals were purified by two consecutive recrystallizations with decolourizing charcoal from methanol/water (5:1) to yield 11.6 g of snow-white crystals and 3.44 g of off-white second-crop crystals of the title compound having the formula: ##STR4##

The melting point was 116.7-117.3° C. The elemental analysis for C₂ OH₁₂ N₂ O₂ was calc.: C, 76.91%, H, 3.87%, N, 8.97%, found: C, 76.90%, H, 3.84%, N, 8.94%.

EXAMPLE 2 Preparation of 1,2-bis-(3-cyanophenoxy) benzene

The compound 1,2-bis(3-cyanophenoxy)benzene was synthesized from 3-flourobenzonitrile and catechol by a procedure identical to that used to prepare 1,2-bis(4-cyanophenoxy)benzene according to Example 1 above. The crude product was in the form of brown crystals which were purified by two consecutive recrystallizations with decolourizing charcoal from methanol/water (5:1) to give 70.44% yield of the title compound with the formula: ##STR5##

The melting point was 99.2-99.7° C. The elemental analysis for C₂ OH₁₂ N₂ O₂ was calc.: C, 76.91%, H, 3.87%, N, 8.97%, found: C, 77.17%, H, 3.81%, N, 8.93%.

EXAMPLE 3 Preparation of 1,2-bis-(2-cyanophenoxy) benzene

The compound 1,2-Bis(2-cyanophenoxy)benzene was synthesized in the same manner as for 1,2-bis-(4-4-cyanophenoxy)benzene according to Example 1 above, but from 2-fluorobenzonitrile and catechol, except that the synthesis was performed in DMF at 125° C. and over a period of 10 hours. The precipitate was filtered off and washed several times with deionised water. The white product was recrystallized from methanol/water (8:1). The yield was 84.6% of the title compound with the formula: ##STR6##

The melting point was 105.4-105.8° C. The elemental analysis for C₂ OH₁₂ N₂ O₂ was calc.: C, 76.91%, H, 3.87%, N, 8.97%, found: C, 77.07%, H, 3.85%, N, 9.02%.

EXAMPLE 4 Preparation of 2,3-bis-(4-cyanophenoxy) naphthalene

To prepare 2,3-bis-(4-cyanophenoxy)naphthalene, 2,3-dihydroxynaphthalene was reacted with 4-fluorobenzonitrile according to the procedure described in Example 1. The product was recrystallized from ethanol/water (15:1). The yield was 89.22% of the title compound with the formula: ##STR7##

The melting point was 137.5-138.2° C. The elemental analysis for C₂₄ H₁₄ N₂ O₂ was calc.: C, 79.54%, H, 3.89%, N, 7.73%, found: C, 79.59%, H, 3.88%, N, 7.70%.

EXAMPLE 5 Preparation of 2,3-bis-(3-cyanophenoxy)-3-naphthalene

To prepare 2,3-bis-(3-cyanophenoxy)naphthalene, 2,3-dihydroxynaphthalene was reacted with 3-fluoronitrile according to the procedure described in Example 1. The product was recrystallized from ethanol. The yield was 51.4% of the title compound with the formula: ##STR8##

The melting point was 157-158° C. The elemental analysis for C₂₄ H₁₄ N₂ O₂ was calc.: C, 79.54%, H, 3.89%, N, 7.73%, found: C, 79.77%, H, 3.88%, N, 7.71%.

EXAMPLE 6 Preparation of 1,2-bis-(4-cyanophenoxy)-3-fluorobenzene

The compound 1,2-bis-(4-cyanophenoxy)-3-fluorobenzene was prepared according to the procedure described in Example 1 by reacting 4-fluorobenzonitrile with 1,2-dihydroxy-3-fluorobenzonitrile. The product was recrystallized from ethanol/water (4:1). The yield was 89.4% of the title compound with the formula: ##STR9##

The melting point was 98-99° C. The elemental analysis for C₂₀ H₁₁ FN₂ O₂ : was calc: C, 72.72%, H, 3.35%, N, 8.48%, found: C, 72.39%, H, 3.28%, N, 8.38%.

EXAMPLE 7 Preparation of 1,2-bis-(4-cyanophenoxy)-3,5-di-tert-butylbenzene

The compound 4-fluoronitrile was reacted with 1,2-dihydroxy-3,5-di-tert-butyl benzene according to the procedure of Example 1. The product was recrystallized from ethanol to give 90.0% yield of the compound with the formula: ##STR10##

The melting point was 187-188° C. The elemental analysis for C₂₆ H₂₈ N₂ O₂ : was calc: C, 79.21%, H, 6.64%, N, 6.60%, found: C, 79.20%, H, 6.62%, N, 6.58%.

EXAMPLE 8 Preparation of 1,2-bis-(3-cyanophenoxy)-3,5-di-tert-butylbenzene

The compound 3-fluoronitrile was reacted with 1,2-dihydroxy-3,5-di-tert-butylbenzene according to the procedure of Example 1. The product was recrystallized from methanol. The yield was 52.38% of the title compound with the formula: ##STR11##

The melting point was 118-119° C. The elemental analysis for C₂₆ H₂₈ N₂ O₂ : was calc: C, 79.21%, H, 6.64%, N, 6.60%, found: C, 79.38%, H, 6.67%, N, 6.58.

EXAMPLE 9 Preparation of 1,2-bis-(2-cyanophenoxy)-3,5-di-tert-butylbenzene

The compound 1,2-bis-(2-cyanophenoxy)-3,5-di-tert-butylbenzene was prepared, according to the procedure of Example 1, by reacting 2-fluorobenzonitrile with 1,2-dihydroxy-3,5-di-tert-butyl benzene. The product was recrystallized from ethanol to give a 90.1% yield of the title compound with the formula: ##STR12##

The melting point was 172-173° C. The elemental analysis for C₂₆ H₂₈ N₂ O₂ : was calc: C, 79.21%, H, 6.64%, N, 6.60%, found: C, 79.20%, H, 6.66%, N, 6.57%.

EXAMPLE 10 Preparation of 1,2-bis-(4-cyanophenoxy)-4-tert-butylbenzene

The compound 4-fluorobenzonitrile was reacted with 4-tert-butylcatechol according to the procedure of Example 1. The product was recrystallized from methanol/water (3:1) to give a 96.1% yield of the title compound with the formula: ##STR13##

The melting point was 119-120° C. The elemental analysis for C₂₃ H₂ N₂ O₂ : was calc: C, 78.24%, H, 5.47%, N, 7.60%, found: C, 78.44%, H, 5.46%, N, 7.58%.

EXAMPLE 11 Preparation of 1,2-bis-(4-carboxyphenoxy) benzene (POP diacid)

In a round-bottomed flask was placed 11.5 g (0.0368 mol) of 1,2-bis(4-cyanophenoxy)benzene, prepared as described in Example 1, together with 20 g (0.35 mol) of potassium hydroxide, 20 mL water and 40 mL methanol. The mixture was refluxed for 16 hours until the evolution of ammonia ceased. The solution was then diluted to 1.0 l with water and was acidified with concentrated HCl to pH 1.5. The white diacid was filtered off, washed with water, and while wet, was recrystallized from 300 mL acetic acid to yield 10.84 g (84.16% yield) of snow-white crystals of 1,2-bis-(4-carboxyphenoxy) benzene with the formula: ##STR14##

The product had a melting point of 257-258° C. The elemental analysis for C₂₀ H₁₄ O₆ : was calc: C, 68.57%, H, 4.03%, found: C, 68.57%, H, 4.02%.

EXAMPLE 12 Preparation of 1,2-bis-(3-carboxyphenoxy) benzene (MOM diacid)

The title compound was prepared by hydrolysing 1,2-bis(2-cyanophenoxy)benzene (prepared as in Example 2) according to the procedure of Example 11. The yield was 99.28% of 1,2-bis-(3-carboxyphenoxy) benzene with the formula: ##STR15##

The product had a melting point of 265-267° C. The elemental analysis for C₂₀ H₁₄ O₆ : was calc: C, 68.57%, H, 4.03%, found: C, 668.49%, H, 3.99%.

EXAMPLE 13 Preparation of 1,2-bis-(2-carboxyphenoxy) benzene (OOO diacid)

The title compound was prepared by hydrolysing 1,2-bis(2-cyanophenoxy)benzene (prepared in Example 3) according to the procedure of Example 11. The product was recrystallized from THF/cyclohexane (1:2) to give a 89.53% yield of 1,2-bis-(2-carboxyphenoxy) benzene with the formula: ##STR16##

The product had a melting point of 184-185° C. The elemental analysis for C₂₀ H₁₄ O₆ : was calc: C, 68.57%, H, 4.03%, found: C, 68.60%, H, 3.97%.

EXAMPLE 14 Preparation of 2,3-bis-(4-carboxyphenoxy) naphthalene (PNOP diacid)

The title compound was prepared by hydrolysing 2,3-bis-(4-cyanophenoxy)naphthalene (prepared in Example 4) according to the procedure of Example 11. The product was recrystallized from acetic acid to give a 87.4% yield of 2,3-bis-(4-carboxyphenoxy)naphthalene with the formula: ##STR17##

The product, after sublimation, had a melting point of 282-285° C. The elemental analysis for C₂₄ H₁₆ O₆ : was calc: C, 72.00%, H, 4.03%, found: C, 71.53%, H, 3.93%.

EXAMPLE 15 Preparation of 2,3-bis-(3-carboxyphenoxy) naphthalene (MNOM diacid)

The title compound was prepared by hydrolysing 2,3-bis-(3-cyanophenoxy)naphthalene (prepared in Example 5) according to the procedure of Example 11. The product was recrystallized from acetic acid to give a 88.5% yield of 2,3-bis-(3-carboxyphenoxy)naphthalene with the formula: ##STR18##

The product, after sublimation, had a melting point of 260-262° C. The elemental analysis for C₂₄ H₁₆ O₆ : was calc: C, 72.00%, H, 4.03%, found: C, 72.14%, H, 3.98%.

EXAMPLE 16 Preparation of 1,2-bis-(2-carboxyphenoxy)-3-fluorobenzene (M3FOM diacid)

The title compound was prepared by hydrolysing 1,2-bis-(4-cyanophenoxy)-3-fluorobenzene (prepared in Example 6) according to the procedure of Example 11. The product was recrystallized from acetic acid/water (3:2) to give a 92.3% yield of 1,2-bis-(2-carboxyphenoxy)-3-fluorobenzene with the formula: ##STR19##

The product, after sublimation, had a melting point of 207-210° C. The elemental analysis for C₂₀ H₁₃ FO₆ : was calc: C, 65.22%, H, 3.55%, found: C, 65.15%, H, 3.58%.

EXAMPLE 17 Preparation of 1,2-bis-(4-carboxyphenoxy)-3,5-di-tert-butylbenzene (P35DTBOP diacid)

The title compound was prepared by hydrolysing 1,2-bis-(4-cyanophenoxy)-3,5-di-tert-butylbenzene (prepared in Example 7) according to the procedure of Example 11. The product was recrystallized from acetic acid to give a 87% yield of 1,2-bis-(4-carboxyphenoxy)-3,5-di-tert-butylbenzene with the formula: ##STR20##

The product had a melting point of 251-252° C. The elemental analysis for C₂₆ H₃₀ O₆ : was calc: C, 72.70%, H, 6.53%, found: C, 72.83%, H, 6.53%.

EXAMPLE 18 Preparation of 1,2-bis-(2-carboxyphenoxy)-3,5-di-tert-butylbenzene (O35DTBOO diacid)

The title compound was prepared by hydrolysing 1,2-bis-(2-cyanophenoxy)-3,5-di-tert-butylbenzene (prepared in Example 9) according to the procedure of Example 11; the hydrolysis proceeded extremely slowly. The product was recrystallized from acetic acid to yield of 1,2-bis-(2-carboxyphenoxy)-3,5-di-tert-butylbenzene with the formula: ##STR21##

The product, after sublimation, had a melting point of 265-267° C. The elemental analysis for C₂₆ H₃₀ O₆ : was calc: C, 72.70%, H, 6.53%, found: C, 72.81%, H, 6.53%.

EXAMPLE 19 Preparation of 1,2-bis-(4-carboxyphenoxy)-4-tert-butylbenzene (P3TBOP diacid)

The title compound was prepared by hydrolysing 1,2-bis-(4-cyanophenoxy)-4-tert-butylbenzene (prepared in Example 10) according to the procedure of Example 11. The product was recrystallize from acetic acid/water (3:2) to give a 90.6% yield of 1,2-bis-(4-carboxyphenoxy)-4-tert-butylbenzene with the formula: ##STR22##

The product, after sublimation, had a melting point of 231-232° C. The elemental analysis for C₂₃ H₂₂ O₆ : was calc: C, 70.92%, H, 5.54%, found: C, 70.99%, H, 5.47%.

EXAMPLE 20 Preparation of 1,2-bis-(4-carboxyphenoxy)benzene dichloride (POP diacid chloride)

Ten mmol of the diacid 1,2-bis-(4-carboxyphenoxy)benzene, prepared in Example 11, was boiled under reflux in a nitrogen atmosphere with about 20 mmol of thionyl chloride for 2 hours. The reflux condenser was protected with a calcium chloride guard tube. Excess thionyl chloride was distilled off, heating with a water bath, under vacuum which was finally reduced to 0.2-0.5 torr. The resulting, crude acid chloride was then dissolved in 50 mL cyclohexane of which about one third was then distilled off and the residual solution left to crystallize. The crude acid chloride was sublimed from a thoroughly degassed melt at about 200° C. at 0.5 torr pressure. The yield was 81.4% of diacid chloride with the formula: ##STR23##

The product, after sublimation, had a melting point of 93-95° C. The elemental analysis for C₂₀ H₁₂ C₁₂ O₄ was calc: C, 62.03%, H, 3.12%, Cl, 18.31%, found: C, 61.77%, H, 3.12%, Cl, 17.54%.

EXAMPLE 21 Preparation of 1,2-bis-(3-carboxyphenoxy)benzene dichloride (MOM diacid chloride)

10 mmol of the diacid 1,2-bis-(3-carboxyphenoxy)benzene, prepared in Example 12, was reacted with of thionyl chloride according to the procedure described in Example 20. The result was a 63.3% yield of acid chloride of formula: ##STR24##

The product, after sublimation, had a melting point of 74-76° C. The elemental analysis for C₂₀ H₁₂ C₁₂ O₄ was calc: C, 62.03%, H, 3.12%, Cl, 18.31%, found: C, 61.89%, H, 3.12%, Cl, 17.47%.

EXAMPLE 22 Preparation of 2,3-bis-(4-carboxyphenoxy) naphthalene dichloride (PNOP diacid chloride)

The compound 2,3-bis-(4-carboxyphenoxy)naphthalene dichloride was prepared by reacting 2,3-bis-(4-carboxyphenoxy)naphthalene with thionyl chloride according to the procedure of Example 20. After initial crystallization, the product was again recrystallized from cyclohexane/toluene (1;1) to give a 96.5% yield of the title compound with the formula: ##STR25##

The product had a melting point of 113-116° C. The elemental analysis for C₂₄ H₁₄ C₁₂ O₄ : was calc: C, 66.22%, H, 2.77%, Cl, 16.29%, found: C, 66.77%, H, 3.32%, Cl, 15.35%.

EXAMPLE 23 Preparation of 1,2-bis-(4-carboxyphenoxy)-3,5-di-tert-butylbenzene dichloride (P35DTBOP diacid chloride)

The compound 1,2-bis-(4-carboxyphenoxy)-3,5-di-tert-butylbenzene dichloride was prepared from 1,2-bis-(4-carboxyphenoxy)-3,5-di-tert-butylbenzene according to the procedure of Example 20. After initial crystallization, the product was recrystallized from a minimum of cyclohexane to give a 81.8% yield of product with the formula: ##STR26##

The product had a melting point of 157-160° C. The elemental analysis for C₂₆ H₂₈ C₁₂ O₄ : was calc: C, 67.33%, H, 5.65%, Cl, 14,19%, found: C, 67.63%, H, 5.82%, Cl, 13.62%.

EXAMPLE 24 Preparation of 1,2-bis-(4-carboxyphenoxy)-4-tert-butylbenzene dichloride (P3TBOP diacid chloride)

The procedure of Example 23 was used to prepare 1,2-bis-(4-carboxyphenoxy)-4-tert-butylbenzene dichloride from 1,2-bis-(4-carboxyphenoxy)-4-tert-butylbenzene and thionyl chloride to give a 65.6% yield of the title compound with the formula: ##STR27##

The product had a melting point of 107-110° C. The elemental analysis for C₂₃ H₂₀ C₁₂ O₄ : was calc: C, 65.02%, H, 4.54%, Cl, 15.99%, found: C, 65.54%, H, 4.80%, Cl, 17.27%

Syntheses of Polyamides

Poly(ether amide) copolymers, derived from the catechol-based diacids synthesized in Examples 11-19, were synthesized by different procedures, as described in full in Examples 25 and 26. Any variations with respect to the procedures are cited in the subsequent specific examples. The phosphorylation technique (Examples 25A-E), described by Yamazaki, N., Higashi, F. and Kawabata, J., J. Polym. Sci., Polym. Chem. Ed., 1974 vol. 12, at 2149; Higashi, F., Ogata, S. I. and Aoki, Y., J. Polym. Sci., Polym. Chem. Ed., 1982, vol. 20, at 2081, was used to demonstrate the feasibility of preparing polyamides from the several acids mentioned, but, under the reaction conditions used, results in low molecular weight polymer. Polymers of higher molecular weight were prepared by first converting the acids to acid chlorides, as described in Examples 20-24, and reacting the acid chloride with a diamine (Examples 26A-P); specific examples are cited in Table 2.

The diamines used in the several syntheses are identified by a code in the titles of the Examples and by their structural formulae in Table 1. The characterization details of the poly(ether-amides) prepared are given in Tables 2 and 3 and, in these and other tables, the diacids used are identified by a code given with the systematic names of the anhydrides in Examples 25-29.

EXAMPLES 25(A-E) Preparations of Polymers by the Phosphorylation Technique EXAMPLE 25A Preparation of Polymer from 1,2-bis-(4-carboxyphenoxy)benzene (POPCAc) and p-Phenylene Diamine (PPD)

In 13 mL of anhydrous NMP (under a nitrogen atmosphere) was dissolved 0.6 g of anhydrous calcium chloride and 0.2 g of lithium chloride. Then 4 mL of anhydrous pyridine was added, followed by 0.70 g of 1,2-bis-(4-carboxyphenoxy)benzene (2 mmol) and 2 mmol of para-phenylene diamine. The mixture was stirred under nitrogen and 2 mL of triphenyl phosphite was added and the temperature was raised to 105° C. for 5 hours when an additional 1 mL of triphenyl phosphite and 1 mL pyridine were added and the mixture was stirred at 110° C. The viscous liquid was then poured into 300 mL of methanol/water (80/20). The polymer was filtered off and extracted with boiling methanol for 1 hour. The yield of polymer was 0.78 g. The M. Wt. (kg mol⁻¹) was 39, the Tg (° C.) was 210 and the TGA weight loss was 98% in the temperature range 390-643.

The same procedure was used for Examples 25B-E.

EXAMPLES 26A-Q Preparations of Polymers Using Preformed Acid Chloride

These were performed using the typical procedure of Example 26A.

EXAMPLE 26A Preparation of Polymers from 1,2-bis-(4-carboxyphenoxy) Benzene Dichloride and p-Phenylene Diamine

One mmol of PPD was dissolved in 7 mL DMAC containing 8.7% CaCl₂ and 0.7 mL pyridine. The mixture was cooled to -14° C. and solid 1,2-bis-(4-carboxyphenoxy)benzene dichloride (1 mmol) was added. The mixture was stirred vigorously for 2.5 hr during which period it became very viscous. The mixture was then kept overnight at -0° C. in a fridge, followed by 24 hr at room temperature. The polymer was precipitated into MeOH/H₂ O, twice extracted with boiling MeOH and dried.

Syntheses of Aromatic Polyesters and Copolyesters

Polyarylates, derived from the catechol-based diacids synthesized in Examples 11-19, were synthesized by different procedures as described in full in Examples 27 and 28; any variations for each of the procedures are cited in the subsequent specific examples.

EXAMPLES 27 Preparation of Polyarylates by Transesterification

Three mmol of a diacid and 3.0 mmol of a diol diacetate together with 0.002 g of dibutyltin oxide were melted and stirred under nitrogen with 3-4 g of m-terphenyl. Within 1-1.5 hr the temperature was raised to 340° C. The reaction was run for 5-8 hours while gradually raising the temperature to 370-380° C. After cooling to about 110° C. the viscous melt was poured into acetone or into toluene/methanol (40/60). The polymer was filtered off and extracted with boiling acetone or methanol and dried. Yields of polymer were about 80%. The polymers and copolymers were subjected to preliminary testing for solubility and for ability to pull fibres from the melt.

EXAMPLE 28 Preparation of Polyarylates by Reaction of Acid Chloride

In order to form polyesters using acid chlorides, 1.0 mmol of acid chloride and 1.0 mmol of diol were refluxed together in dichlorobenzene for 3 hours. The polymer was isolated by precipitation into methanol, was extracted with methanol and dried. An example is given in Table 3.

EXAMPLE 29 Preparation of Copolyarylates by transesterification

Exactly the same reaction conditions were applied as for Example 27, except that hdyroxybenzoic acid was added in different proportions such that there was an overall stoichiometric balance of acid and hydroxyl, or protected hydroxyl functionality. Details of Examples are given in Table 4.

EXAMPLE 30 Synthesis of 1,2-bis(4-aminophenoxy)benzene POP Amine)

A. Synthesis of intermediate 1,2-bis(4-nitrophenoxy)benzene

In a three-necked round-bottomed flask equipped with nitrogen inlet, thermometer and Dean-Stark trap with reflux condenser was placed 22 g (0.2 mole) catechol (Aldrich), 250 mL DMF, 64 g (0.4 mole+7.6 g excess) p-nitrofluorobenzene (Fluorochem), 80 g potassium carbonate (anhydrous) and 50 mL xylene. The mixture was refluxed under a nitrogen atmosphere for 5 hours, then, within 2.5 hours, 100 mL of liquid (xylene plus DMF) was distilled off and the hot liquid was poured into 2.0 l ice/water mixture with vigorous stirring. The resulting brown solid was filtered off and thoroughly washed with deionized water until neutral. The wet cake was boiled in 1200 mL ethanol and left to crystallize overnight to yield (including a second crop) 65 g (92.32% theoretical) of yellow crystals. Melting point 134-135° C. Elemental analysis: Calc: C, 61.36%, H, 3.43%, 7.95%; Found: C, 61.34%, H, 3.43%, 7.92%.

B. Synthesis of 1,2-bis(4-aminophenoxy)benzene (POP amine)

In a 3 l round-bottomed flask equipped with a magnetic stirrer bar, reflux condenser and dropping funnel was placed 64.20 g (0.182 mol) of 1,2-bis(4-nitrophenoxy)benzene (SI-319), 700 mL ethanol and 2 g 5% palladium on charcoal. The mixture was brought to boil when 200 mL of hydrazine hydrate was added dropwise during a period of 1.5 hours. The mixture was refluxed for a further 3 hours. The hot mixture was then filtered over a filter agent and left to 10 crystallize. The next day the crystals were separated and the liquid volume reduced to 400 mL, from which an additional crop of crystals was filtered off. The combined crystalline product was recrystallized twice from methanol/water (3:1) to yield 41.2 g of off-white crystals. By reducing the liquid volume a second crop of 5.7 g of crystals was obtained (overall yield 88.17% theoretical). Melting point 135-136° C. Elemental analysis: Calc: C, 73.95%, H, 5.51%, 9.59%; Found: C, 74.10%, H, 5.62%, 9.77%.

                  TABLE 1                                                          ______________________________________                                         Example   Diacid    Diamine   Comments                                         ______________________________________                                         25A       POP       MPD       Fusible, forms fibres.                                                         Sol. DMF                                         25B       MOM       PPD       Fusible, forms fibres.                                                         Sol. NMP                                         25D       MOM       MPD       Forms fibres Sol. NMP                            25D       OOO       PPD       Forms fibres Sol. NMP                            25E       OOO       MPD       Forms fibres Sol. NMP                            ______________________________________                                          PPD = paraphenylene diamine                                                    MPD = metaphenylene diamine                                              

                                      TABLE 2                                      __________________________________________________________________________                                TGA                                                    Diacid     M. Wt.   I.V./                                                                              incipient wt.                                                                        residue at                                    Ex.                                                                               chloride                                                                             Diamine                                                                             kg mol-1                                                                            Tg/° C.                                                                     (dl g-l)                                                                           loss, ° C.                                                                    600° C.                                                                      Comments                                 __________________________________________________________________________     26A                                                                               POP   PPD  75   280 1.16                                                                               490   41   Not fusible                                                                    Sol. NMP                                 26B                                                                               POP   MPD  104  221 1.18                                                                               390   60   Fusible,                                                                       forms short                                                                    fibres. Sol.                                                                   NMP                                      26C                                                                               POP   POP  111  192 1.11                                                                               425   46   Nonfusible                                                                     Sol. NMP                                 26D                                                                               MOM   MPD                          Long fibres                                                                    Sol NMP                                  26E                                                                               P3TBOP                                                                               PPD       250 0.70                                                                               415   55                                            26F                                                                               P3TBOP                                                                               MPD       217 0.54                                                                               380   47                                            26G                                                                               P3TBOP                                                                               POP       194 0.32                                                                               420   44                                            26H                                                                               PNOP  PPD       235 0.32                                                                               410   54                                            26I                                                                               PNOP  MPD       246 insol                                                                              410   67                                            26J                                                                               PNOP  POP       201 0.63                                                                               420   93                                            26K                                                                               P35DTBOP                                                                             PPD       269 0.60                                                                               415   42                                            26L                                                                               P35DTBOP                                                                             MPD       247 0.07                                                                               410   47                                            26M                                                                               P35DTB-OP                                                                            POP       218 0.65                                                                               420   40                                            26N                                                                               IPA   POP                          Long fibres,                                                                   Sol. NMP                                 26O                                                                               TPA   POP                          Plastic melt,                                                                  No fibres                                                                      pulled Sol.                                                                    NMP                                      26P                                                                               IPA   MOM                          Long fibres,                                                                   Sol. NMP                                 26Q                                                                               TPA   MOM                          Non-fusible,                                                                   no fibres Sol.                                                                 NMP                                      __________________________________________________________________________      IPA = isophthalic acid; TPA = terephthalic acid; PPD = paraphenylene           diamine;                                                                       MPD = metaphenylene diamine.                                             

                  TABLE 3                                                          ______________________________________                                         Polyarylates Formed by Transesterification                                     Example                                                                               Diacid     Diacetate Comments                                           ______________________________________                                         27A    POP        HQ        Sol. in boiling                                                                dichlorobenzene                                    27B    POP        RES       V. sol. in THF.                                                                Fibres from melt. Solvent                                                      plasticised                                        27C    MOM        HQ        Short brittle fibres                                                           from melt                                          27D    F3TBOP     HQ        Sol. in chloroform, very                                                       long fibres from melt.                             27E    PNOP       HQ        Sol. in chloroform, long                                                       fibres from melt                                   27F    P35DTBOP   HQ        Sol. in chloroform, long                                                       fibres from melt.                                  28A    POP        HQ        Fusible, forms short                                                           fibres near decomp. temp. Sol                                                  NMP                                                ______________________________________                                          HQ = hydroquinone; RES = resorcinol.                                     

                  TABLE 4                                                          ______________________________________                                         Copolyarylates                                                                 Example                                                                               Diacid   Other reagents                                                                            Comments                                            ______________________________________                                         29A    POP      HQ (0.25), Opaque soln. in NMP, fusible,                              (0.25)   HDA (0.5)  long fibres from melt (>10 in),                                                exhibits liquid crystallinity.                      29B    P3TBOP   HQ (0.15), Soluble in hot cresol,                                              HBA (0.7)  dichloroacetic acid, or NMP,                               (0.15)              opaque solutions, v. short fibres                                              pulled from melt                                    ______________________________________                                          HBA = hydroxybenzoic acid; HQ = diacetate of hydroquinone.                

What is claimed is:
 1. A polymer comprising the repeat unit ##STR28## wherein Ar¹ is arylene or alkyl- or halo-substituted arylene and in which the ether oxygen atoms are substituted on Ar¹ in ortho positions, said polymer further comprising at least one other repeat unit such that said polymer is a polyester, a fusible polyamide or a poly(amide-ester).
 2. The polymer as recited in claim 1 which is a polyester.
 3. The polymer as recited in claim 1 which is a polyamide.
 4. The polymer as recited in claim 1 which is a poly(amide-ester).
 5. The polymer as recited in claim 1 wherein Ar¹ is o-phenylene.
 6. The polymer as recited in claim 1 wherein Ar¹ is substituted with alkyl or halogen.
 7. The polymer as recited in claim 1 wherein Ar¹ is o-phenylene or 2,3-naphthylene.
 8. The polymer as recited in claim 1 wherein Ar¹ is 3,4-di-t-butyl-o-phenylene, 3-fluoro-o-phenylene or 4-t-butyl-o-phenylene.
 9. The polymer, as recited in claim 1 wherein said carbonyl groups are para said ether atoms.
 10. The polymer as recited in claim 9 which is a polyester.
 11. The polymer as recited in claim 9 which is a polyamide.
 12. The polymer as recited in claim 9 which is a poly(amide-ester).
 13. The polymer as recited in claim 9 wherein Ar¹ is o-phenylene.
 14. The polymer as recited in claim 9 wherein Ar¹ is substituted with alkyl or halogen.
 15. The polymer as recited in claim 9 wherein Ar¹ is o-phenylene or 2,3-naphthylene.
 16. The polymer as recited in claim 9 wherein Ar¹ is 3,4-di-t-butyl-o-phenylene, 3-fluoro-o-phenylene or 4-t-butyl-o-phenylene. 